Resin composition and method of



than 138x10 at 25 degrees centiarade.

PatentcdDeczfiJm 'UNITED STATES PATENT OFFICE RESIN COMPOSITION ANDrun-non OI MAKING m sun:

lC'Ialma.

This invenflon is a rcainous compositionproducedi'romanrixtureoiapoiymerisableruran derivative and a resinsoluble therein.

It has been discovered that the.polymerizable iuriuryl alcohol is a modsolvent for such resins as polyvinyl acetal. p y inyl butyral, etc., thepolyalky] acrylates and poly-methacrylates, "A-staae" phenol-aldehyderesin, cashew nut oil, resins, asphalts. and the like. The resins listedare illustrative of materials soluble in iuriuryl alcohol. Therefore,whenever "a resin soluble in turiuryl alcohol" is hereinafter referredto in the specification or claims, it is intended to include in suchterm any or the material above identifled. or any other resin soluble inl'uriuryl alcohol.

These compositions when dissolved in ruriuryl alcohol, for example, arefairly stable liquids oi "W 8 dearces oi viscosity. depending upon thparticular resin and the perccntase thereof which is dissolved in theiuriuryl alcohol. These more or less viscous liquid compositions areeasily polymeriscd, at room temperatures, to veryhighaoIteninc-point-reslnous-solids by the addition of oraanic acidcatalysts. rminstance, formic acid. lactic acid. para toluene sulphonlcacid, para toluene sulpho chloride, aryl alkyl sulphates and chlorides,chior acetic acid, malic acid, maleic acid. tartaric acid and phthallcacid, which may be taken as illustrative oi organic acid catalysts, allof which have an ionization constant q l to or areater than lactic acidwhich has an ionization constant oi 138x 10- at degrees centin'ade. haveall been iound satisfactory. Therefore. wherever the term "acidcatalyst" is used without qualification. it is intended to include anyorganic acid or oraanic acid compound which has an ionization constantequal to or :reIater t is preierred to use para toluene sulphonic acidor para toluene aulp o chloride.

These polymerized hish-soitenina-poi t-prodnets are somewhat similar tothe phenol-tormaldehyde resins, with the two important advantaaes thatpolymerized compositions are obtainable oi almost any degree orflexibility. and which are inert to alkalies of all concentrations. The

water the content of iuriuryl alcohol in these Example I February 27,1941.

100 parts by wcislit 01 a resin composition con- Sistine o! a mixture or05% i'uriuryl alcohol and 6% of polyvinyl butyral, or other resinsoluble in iurruryl alcohol. mixed with 195 parts by weight 0! carbonand 5 parts by weight 01 para toluene sulphonic acid, or 10 parts byweight of para toluene sulpho chloride.

Example I] 100 parts by weight of a resinous composition consisting oilurluryl alcohol, 16% iuriuryl aldehyde and 30% poly butyl methacrylate(or other soluble resin), mixed with 195 parts by weizht at carbon, and10 parts by weight oi para toluene sulpho chloride.

The above examples are zlven for purposes 0! Illustration. and it is tobe understood that the relative proportions given may be varied withoutdeparting from the spirit of the invention.

Such a cement is excellent for the Joining oi bricks in the constructionoi corrosion-proof tank llnlnas, floors and the like. Quite obviously,the pcrcentaze composition at the materials listed above may be variedover a wide reuse to produce cements or desired physical and chemicalproperties. The cement above described remains workable forapproximately thirty minutes at room temperature. then hardens andpolymerization is complete in approximately twenty-four hours. Inpractice. itis desirable that the mixture remain workable ior at leastthirty minutes, and it is easier to obtain this workability when oraanicacids are used as catalysts instead of inorganlc acids. Incidentally,acid-producing substancesmay also be used instead of the acids beingused directly.

In the iahrication of these cements. it is important to have a liquidresin composition or a viscosity which gives a good workable cement. Forthis purpose, viscosities ranging from 4 to seconds (Gardner 8: Hoidt)have been iound to be quite satisiactory. Such resin compositions may beused to cast corrosion-prooi tanks or other equipment from them in suchmanner as one constructs equipment oi reinforced concrete. Thereinlorcement could be embedded in the resin cement in the usual manner,or the tank could be supported by steel or alloy angles around theoutside. For this work it may be desirable to replace the carbon withilber or leave fillers out oi the composition entirely. They may also beused advantaaeously for the protection of porous surfaces. such as woodor leather. In either instance, the material is coated with a mixture oiiuriuryl alcohol and resin. and a catalyst, and then lymerisadinsitu.

If s me flexible cement is required, the percentaae of polyvinylbuiyral, or other soluble resin is increased and the percentage offiller is decreased. or the filler may be entirely eliminated The moreflexible compositions may prove more satisiaciory when the material isapplied to steel, concrete or the like as a thin coating. Thesematerials may also be applied as coatings to steel. cast iron. concreteor the transite pipe. As a primer on metallic and other surfaces. it hasbeen found that derivatives or isomers of rubber, as well as Bakelitepaints. work very well. Such coatings are also of value for the liningof tanks used ior holding hot water in homes. In some applications it isdesirable to mix these compositions with toluene or other evaporablesolvents with which they are mlscible. By evaporable solvents is meantthose solvents which will evaporate at room temperature and which aremiscible with turiuryl alcohol, such as alcohol, carbon tetrachloride,and ethylene dichloride.

Instead oi the polymerized resins, such as polyvinyl butyral. themethacrylates or acrylates having an alkyl group of butyl or larger, maybe used. and the composition polymerized by the addition oi acid and acatalyst for the conversion oi these monomers to the polymers. Butylmethacrylates and butyl acrylates may be considered as examples of themethacrylate and acrylate monomers. and benzoyl peroxide is an exampleof the proper type oi catalyst.

The resinous compositions made in accordance with the present inventionis susceptible of many uses, some of which have been enumerated, and itis believed that the inherent advantages thereor, as indicated by thediversity of its uses, will be readily apparent to those skilled in theart to which it appertains.

What we claim is:

1. The method of producing an alkali-acidprooi cement of 4 to 100seconds viscosity which comprises dissolving polyvinyl butyral infuri'uryl alcohol. the quantities thereof being proportioned to producea resin of said viscosity. and then polymerizing the furiuryl alcohol byaddin an organic acid catalyst oi sumciently reduced concentration tomaintain the cement in a workable condition for approximately 30 minutesat room temperature, said catalyst having an ionization constant of notless than 138x10" at 25 C.

2*. The method oi producing an alkali-acidproof cement which comprisesdissolving polyvinyl butyral in an' amount or iuriuryl alcoholproportioned to produce a solution having it via-- cosity of 4 to 100seconds, and then polymerizing the i'uriuryl alcohol by adding an acidcatalyst oi sulliciently reduced concentration to maintaln the cement ina workable condition for approximately 30 minutes at room-temperature.said catalyst having an ionization constant of not less than l.38 l-' at25 C.

3. The method of producing an alkali-acidproof cement which comprisesdissolving polyvinyl butyral in an amount of iuriuryl alcoholproportioned to produce a solution having a viscoslty of 4 to 100seconds. and then polymerizing the iuriuryl alcohol by adding an acidcatalyst or sumciently reduced concentration to maintain the cement in aworkable condition for approximately 30 minutes at room temperature andharden within 24 hours, said catalyst having an ionization constant ofnot less than i.38 at 25' C.

i. The method of producing an alkali-acida,sea,oso

prooi cement which comprises dissolving polyvinyl butyral in an amountor iurruryi alcohol proportioned to produce a solution having aviscosity of 4 to 100 seconds. and then polymerizing the turiurylalcohol by adding an organic acid catalyst of sumciently reducedconcentration to maintain the cement in a workable condition forapproximately 30 minutes at room temperature and harden within 24 hours,said catalyst having an ionization constant of not less than 1.38Xl0- at25 C.

5. The method of producing an alkali-acidproof cement which consists indissolving polyvinyl butyral in iurfuryl alcohol. the quantities thereofbeing proportioned to produce a resin solution oi i to 100 seconds. andthen polymerizing the iuriuryl alcohol by mixing the resin solution withan inert filler and an acid catalyst of sumciently reduced concentrationto maintain the cement in a workable condition [or approximately 30minutes at room temperature. said catalyst having an ionization constantoi not less than 1.38xl0- at 25 C.

6. The method of producing an alkali-acidprooi cement which consists indissolving polyvinyl butyral in iuriuryl alcohol, the quantities thereofbeing proportioned to produce a resin solution oi 4 to 100 seconds, andthen polymerizing the iuriuryl alcohol by mixing the resin solution withan inert filler and an acid catalyst of sumciently reduced concentrationto maintain the cement in a workable condition for approximately 30minutes at room temperature and harden within 24 hours, said catalysthaving an ionization constant of not less than 138x10" at 25 C.

7. The method of producing an alkali-acidproof cement which consists ofproducing a resin solution by dissolving parts by weight of polyvinylbutyral in 95 parts furiuryl alcohol and polymerizing the lurfuryialcohol by mixing the resin solution with approximately 195 parts byweight of carbon and an organic acid catalyst of sumciently reducedconcentration to maintain the mixture in a workable condition for 30minutes at room temperature. said catalyst having an ionization constantof not less than l.38 at C.

8. The method of producing an alkali-acidprooi' cement which consists ofproducing a resin solution by dissolving 5 parts by weight of polyvinylbutyral in 95 parts iuriuryl alcohol and polymerizing the iuriurylalcohol by mixing the resin solution with approximately 195 parts byweight or carbon and approximately 10 parts oi an acid catalyst havingan ionization constant of not less than 138x10" at 25 C., the proportionof said catalyst being such as to cause the mixture to remain plasticfor minutes at room temperature.

9. The method of producing an alkali-acldproof cement which consists oiproducing a resin solution by dissolving 5 parts by weight of polyvinylbutyral in parts iuriuryl alcohol and polymerizing the iuriuryl alcoholby mixing the resin solution with approximately parts by weight orcarbon and approximately 10 parts of an acid catalyst having anionization constant oi not less than LSBXIO- at 25 C., the proportion oisaid catalyst being such as to cause the mixture to remain plastic for30 minutes at room temperature and to harden within 24 hours CLARON R.PAYNE. RAYMOND B. SEYMOUR.

